A brick made from polypropylene and recycled oil that is resistant to moisture and erosion and production method thereof

Abstract

The present invention relates to a brick made from 60 to 70% wt.% of polypropylene, which comprises in its formulation from 30 to 40% wt.% of recycled oil and 0.5 to 3.5% wt.% of expanded polystyrene. The invention comprises the following steps: a) shredding the polypropylene to a particle size less than 2 inches; b) mixing the polypropylene with the recycled oil; c) heating the mixture between 80°C and 180°C for 20 minutes; d) pouring the mixture into a mould to produce bricks; e) incorporating the shredded polystyrene up to the size of spheres that have been previously established in the material; f) finishing the firing of the brick; e) allowing to cool and demoulding the brick.

Description

A BRICK MADE FROM RECYCLED POLYPROPYLENE AND OIL, RESISTANT TO HUMIDITY AND EROSION, AND ITS MANUFACTURING METHOD

[0001] The following invention is developed in the technical field of construction materials, more specifically, in the production of bricks based on polypropylene and used oil.

[0002] Bricks are currently known to be made from various sources or raw materials, which seek to take advantage of their benefits to create bricks with characteristics such as being lightweight, resistant to erosion, moisture, among others.

[0003] Document CN108297264A explains a method for producing waterproof, crack-resistant, low-density, and high-strength insulation blocks. The production method comprises the following sequences: module preparation, preparation of waterproof, crack-resistant concrete, preparation of insulation block molds, insertion of EPS module molds, concrete pouring, steam curing, natural condensation, demolding, and the like.

[0004] Document CN103979912A explains the method of making a corrosion-resistant reinforced brick, which is prepared from the following raw materials by weight: 8-12 parts of modified sawdust, 7-9 parts of gypsum, 50-60 parts of fly ash, 0.4-0.6 parts of polypropylene fibers, 1-2 parts of maltodextrin, 1-2 parts of calcium lignosulfonate, 6-9 parts of active white clay, 0.7-1.2 parts of sucrose, palmitic acid, 0.5-1 part of acetylsalicylic acid, 0.6-1 part of ethanedioic acid, disodium tetraacetic acid, 1-2 parts of sodium polyphosphate, 1-2 parts of ricinoleic acid polyester, 10-14 parts of carbide slag, 8-12 parts of silicate cement, 12-15 parts of lime. live, 5-6 parts of aluminum powder and water.

[0005] According to this invention, the reinforced brick is corrosion-resistant, has a compact structure, antibacterial properties, corrosion resistance, fire resistance, thermal and acoustic insulation properties, dimensional stability, and a low dry shrinkage rate; and modified sawdust is used to improve the thermal insulation effect, reduce weight, enhance anti-seismic properties, and provide a good water-reducing effect.

[0006] Within the document “Design of the production process of bricks based on recycled plastic” (Campos et. al, 2019), three types of mixtures are explained where polyethylene terephthalate is used, in addition to cement, water, sand and stone, obtaining bricks that were evaluated through sizing, absorption, warping, compression tests, whose results complied with what is required by current legal regulations.

[0007] On the page https: / www.imnovation-hub.com / es / construccion / ladrillos-plastico-reciclaje / ?_adin=02055904305, the process of manufacturing bricks from plastics is explained as a recycling alternative, which has 3 fundamental phases: collection of plastics (it can be low-density polyethylene, polyethylene terephthalate or polypropylene), crushing of waste and compaction of the waste into bricks by means of water vapor.

[0008] Document CN103992091B details a high-strength lightweight brick, which is composed, by weight, as follows: 10 - 12 parts cement, 13 - 15 parts quicklime, 7 - 9 parts modified sawdust, 5 - 7 parts gypsum, 40 - 50 parts ash, 4 - 6 parts white zirconium, 4 - 6 parts hollow coal ash microbeads, 2 - 4 parts water glass, 3 - 5 parts calcium carbonate, 1 - 2 parts silicone resin polyether emulsion, 1 - 2 parts barium nanosulphate, 2 - 4 parts glass wool, 3 - 5 parts glass beads, 3 - 5 parts hydrophilic silica and water.

[0009] These bricks use hollow glass beads, hollow coal ash microbeads, and hydrophilic silica to enhance the bricks' strength, fire resistance, heat retention, and soundproofing. Drying shrinkage is low, improving seismic performance. The use of modified sawdust improves thermal insulation, reduces weight, and improves water reduction.

[0010] The aforementioned inventions present the problem of using a low percentage of polypropylene or the use of another plastic or recycled materials, prioritizing the properties and / or functionalities of the final invention, something in which this invention differentiates itself, as it manages to exceed the minimum requirements of the regulations using more than 90% recycled products. Description of the Invention

[0011] As a solution to the aforementioned problems, the present invention was developed: a brick with resistance to moisture and erosion, made from recycled polypropylene and oil from light vehicle engines.

[0012] Bricks made from recycled polypropylene are lighter than conventional clay or cement bricks, which reduces transportation, labor, and the weight of the structure for which they will be used. Furthermore, polypropylene bricks are water-resistant and unaffected by moisture or erosion.

[0013] Polypropylene bricks can be used in a variety of construction applications, such as load-bearing, non-load-bearing, and temporary walls, depending on the characteristics required by regulations such as Standard E070 (NTP 399.609:2013). In addition to their strength and durability, polypropylene bricks are environmentally friendly, as they are manufactured from recycled materials.

[0014] Recycled polypropylene, recycled oil, and expanded polystyrene are used to make bricks. Recycled polypropylene is collected (1) directly from pumps, plastic waste dumps, and retail outlets where soda and water caps have been used. It appears as flat particles of various colors, with a smooth and rough texture, and is crushed (2) to a size less than 2 inches.

[0015] Recycled oil (9) has been obtained from the engine of motorcycles or other light vehicles, which is mixed (4) with the crushed polypropylene, to subsequently incorporate the mixture into a mold suitable for making a brick.

[0016] Once in the mold, the mixture is taken to an oven (5) with a temperature range of 80 °C to 180 °C. When the mixture reaches 180 °C, expanded polystyrene particles (10) are incorporated (6), which were previously crushed (11) manually until reaching the size of the spheres previously established in the material. At the end of the cooking process, the brick is cooled (7), and finally, it is removed from the mold (8).

[0017] Recycled polypropylene and recycled oil are fully blended and have a high melt flow rate for uniform melting. They also feature excellent chemical resistance, low density, high purity, very low moisture absorption, high thermal expansion, and do not suffer from rapid stress cracking.

[0018] To verify the characteristics of the invention, the following tests have been carried out:

[0019] Measurement and Warping Test

[0020] Regulations: Peruvian Technical Standard (NTP 399.613, Masonry Units)

[0021] The dimensions that generate the dimensional variation test of polypropylene bricks (Technical Standard 331.017) in length, width and thickness.

[0022] Compressive strength test

[0023] Regulations: Peruvian Technical Standard (NTP 399.613, Masonry Units)

[0024] The brick was subjected to the compressive strength test (ASTM C62), to determine the warping of the brick piece and thus calculate the contact area that will be subjected to the compression test with which the sample is placed inside the machine, applying pressure constantly until the sample fails, taking record of the amount of force applied and performing the calculation to obtain the compressive strength in Kg / cm2 before failure.

[0025] The acceptance criteria for the compressive strength of building bricks vary depending on the brick class, with first-class bricks having a minimum compressive strength of 10.3 MPa and second-class bricks having a minimum compressive strength of 7.0 MPa.

[0026] Absorption test

[0027] Regulations: Peruvian Technical Standard (NTP 399.604 and 399.613, Masonry Units)

[0028] The brick was also subjected to an absorption test, a standard procedure used to measure the amount of water a brick absorbs (Taus, VL). This test assesses the brick's ability to withstand moisture accurately and uniformly. The procedure involves immersing the brick in water for a specific period of time and then measuring the amount of water absorbed.

[0029] The acceptance criterion for water absorption for first-class bricks should not exceed 15%, while for second-class bricks it should not exceed 22%. Test results can also be used to determine the brick's degree of compactness.

[0030] Suction test

[0031] Regulations: Peruvian Technical Standard (NTP 399.613, Masonry Units)

[0032] The brick was also subjected to the suction test, according to international standards such as ASTM C67 and EN 772-6, which involves measuring the rate and quantity of water absorbed by the brick. The test is performed by placing the brick in a container of water and measuring the weight increase over time. The test results can be used to classify the brick's water absorption properties into one of three categories: low, medium, or high.

[0033] The test results can be used to evaluate the material's durability and resistance to water damage, as well as to assess the bricks' water absorption properties.

[0034] Flowchart of the production process of lightweight bricks based on recycled polypropylene.

[0035] Isometric view of lightweight brick made from polypropylene and recycled oils. PREFERRED EMBODIMENTS OF THE INVENTION

[0036] The examples provided herein serve to illustrate the nature of the present invention. These examples are included for illustrative purposes only and should not be construed as limitations on the invention claimed herein.

[0037] The invention is a brick with resistance to moisture and erosion, which is made from recycled polypropylene (2), in a range of 60% to 70%, more specifically, between 62.5% to 67.5%; and recycled oil (9), in a range of 30% to 40%, more specifically, from 31 to 35%, which are poured into a mold for making bricks, which is taken to a furnace (5) between 80 to 180°C.

[0038] Once 180°C has been reached, the crushed expanded polystyrene (10) (11) is poured onto the mould mixture up to the spheres previously established in the material, in a range of 0.5% to 3.5%, more specifically, between 1.5% and 2.5%. A slight decrease in the temperature of the mixture is expected, which then returns to 180°C, and is left at that temperature for 5 to 8 more minutes to finish cooking the brick.

[0039] Once cooking is complete, the mixture and the mold are allowed to cool (7), and once they reach room temperature, they are removed from the mold (8).

[0040] Tests to determine the functional characteristics and quality of the brick

[0041] The resulting brick was analyzed according to current national and international standards to determine its functional characteristics and quality. Four tests were conducted, yielding the following results:

[0042] Measurement and warping test

[0043] This test was carried out under NTP 399.613, Masonry Units, and the values ​​obtained are within the permissible ranges established by this NTP, yielding the following results:

[0044] [Table 1]TypePrototypeDimensional variation (%)LengthWidthHeightLimit3%(4.5 mm)Complies4% (6 mm)Complies5% (5 mm)CompliesIII1-2.44(-1.47)Yes-0.07(-0.07)Yes2.07 (3.1)YesIII2-0.28(-0.17)Yes1.87 (1.87)Yes3.2(4.8)YesLimit6Complies5Complies3Complies141-2.44(-1.47)Yes-0.07(-0.07)Yes2.07 (3.1)Yes142-0.28(-0.17)Yes1.87 (1.87)Yes3.2(4.8)Yes Compressive strength test

[0045] The test was carried out under NTP 399.613, Masonry Units, and the ASTM C62 compressive strength test. The results were:

[0046] [Table 2]SampleMeasurementsCompressive stress (tn)Compressive stress (Kg / cm2)(fbi-fb)2Max. warping (mm)Length (cm)Width (cm)Height (cm)Area (cm2)1114.6910.0076.147108.29311.26103.98236.220.514.529.8136.014103.77513.98134.71236.2Average strength fb avg12.62119.35472.39Fi21.73Characteristic strength (f'b, in Kg / cm2)97Characteristic strength (f'b, in MPa / cm2)9.7Masonry unit classBrick III

[0047] Given the results, the brick meets the compressive strength tests.

[0048] Absorption test

[0049] It was carried out under NTP 399.604 and NTP 399.613, where we sought to measure the amount of water absorbed by the brick, from which we obtained the following result:

[0050] [Table 3]TypePrototypeAbsorption (%)Limit (%)ComplianceIII12.7322YesIII25.6Yes1412.73No limitYes1425.6Yes

[0051] Suction test

[0052] It was carried out under NTP 399.613, Masonry Units, and the international standards ASTM C67 and EN 772-6. The result was:

[0053] [Table 4] Suction Type III (Normalized) 10 to 20 gr / 200 cm2-min Prototype I 0.00 gr / 200 cm2-min Prototype II 0.00 gr / 200 cm2-min

[0054] The brick did not show any suction, therefore it is in the low category.

Claims

A brick made from polypropylene (2) of the type comprising in its formulation recycled oil (9) and expanded polystyrene (10), characterized in that its manufacturing method comprises the following stages: Grind (3) the polypropylene (2) to a particle size of less than 2 inches; Mix (4) the polypropylene with the recycled oil; Heat (5) the mixture between 80°C and 180°C for 20 minutes; pour the mixture into a mold to make bricks; incorporate (6) the polystyrene (10) crushed (11) to the size of spheres previously established in the material; finish cooking the brick; let it cool (7) and remove the brick (8) from the mold. A brick made from polypropylene according to claim 1, characterized in that the percentage by weight of polypropylene in its formulation is 60% to 70%. A brick made from polypropylene according to claim 1, characterized in that the percentage by weight of recycled oil in its formulation is 30% to 40%. A brick made from polypropylene according to claim 1, characterized in that the percentage by weight of expanded polystyrene in its formulation is from 0.5% to 3.5%.

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